Disassembly and Reassembly
GENERATORDISASSEMBLY
1. REMOVE GENERATOR PULLEY
a. Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque.
SST 09820-63010 (09820-06010, 09820-06020)
Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)
NOTE: Check that SST is secured to the rotor shaft.
b. Mount SST (C) in a vise.
c. Insert SST (B) into SST (C), and attach the pulley nut to SST (C).
d. To loosen the pulley nut, turn SST (A) in the direction shown in the illustration.
NOTE: To prevent damage to the rotor shaft, do not loosen the pulley nut more than one-half of a turn.
e. Remove the generator from SST (C).
f. Turn SST (B), and remove SST (A and B).
g. Remove the pulley nut and pulley.
2. REMOVE REAR END COVER
a. Remove the nut and terminal insulator.
b. Remove the bolt, 3 nuts, plate terminal and end cover.
3. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY
a. Remove the brush holder cover from the brush holder.
b. Remove the 2 screws and brush holder.
4. REMOVE GENERATOR REGULATOR ASSEMBLY
a. Remove the 3 screws and generator regulator.
5. REMOVE GENERATOR HOLDER WITH RECTIFIER
a. Remove the 4 screws and holder with rectifier.
6. REMOVE GENERATOR RECTIFIER END FRAME
a. Remove the 4 rubber insulators.
b. Remove the seal plate.
c. Remove the 4 nuts and cord clip.
d. Using SST, remove the rectifier end frame.
SST 09286-46011
7. REMOVE GENERATOR ROTOR ASSEMBLY
a. Remove the generator washer from the rotor.
b. Remove the rotor from the drive end frame.
NOTE: Do not drop the rotor.
REASSEMBLY
1. INSTALL GENERATOR ROTOR ASSEMBLY
a. Install the generator rotor.
b. Install the generator washer onto the rotor.
2. INSTALL GENERATOR RECTIFIER END FRAME
a. Using a 19 mm socket wrench and press, slowly press in the rectifier end frame.
b. Install the 4 nuts and cord clip.
Torque: 4.5 N.m (46 kgf.cm, 40 in.lbf) for nut A
5.4 N.m (55 kgf.cm, 48 in.lbf) for nut B
c. Install the seal plate onto the rectifier end frame.
d. Install the 4 rubber insulators onto the lead wires.
NOTE: Be careful that the rubber insulators are in the right direction.
3. INSTALL GENERATOR HOLDER WITH RECTIFIER
a. Install the rectifier holder while pushing it with the 4 screws.
Torque: 2.9 N.m (30 kgf.cm, 26 in.lbf)
4. INSTALL GENERATOR REGULATOR ASSEMBLY
a. Install the generator regulator with the 3 screws.
Torque: 2.0 N.m (20 kgf.cm, 18 in.lbf)
5. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY
a. Install the brush holder with the 2 screws.
Torque: 2.0 N.m (20 kgf.cm, 18 in.lbf)
NOTE: Be careful that the holder is in the right direction when installing it.
b. Install the brush holder cover.
6. INSTALL REAR END COVER
a. Install the end cover and plate terminal with the bolt and 3 nuts.
Torque: 3.9 N.m (40 kgf.cm, 34 in.lbf) for bolt
4.4 N.m (45 kgf.cm, 39 in.lbf) for nut
b. Install the terminal insulator with the nut.
Torque: 4.1 N.m (42 kgf.cm, 36 in.lbf)
7. INSTALL GENERATOR PULLEY
a. Install the pulley to the rotor shaft by tightening the pulley nut by hand.
b. Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque.
SST 09820-63010 (09820-06010, 09820-06020)
Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)
c. Check that SST (A) is secured to the pulley shaft.
d. Mount SST (C) in a vise.
e. Insert SST (B) into SST (C), and attach the pulley nut to SST (C).
f. To torque the pulley nut, turn SST (A) in the direction shown in the illustration.
Torque: 133 N.m (1,356 kgf.cm, 98 ft.lbf)
g. Remove the generator from SST (C).
h. Turn SST (B), and remove SST (A and B).